Volkswagen Golf Variant / Jetta. Manual - part 492

– Slide the safeguard on the Fiber-Optic Repair Set - Pliers -

VAS6223/1- in direction of the -arrow- so that the word

“Stift” (pin) is legible.

– Insert a brass pin contact -1- in the mount.
– Close the securing lever on the Fiber-Optic Repair Set - Pliers

- VAS6223/1- in the direction of the -arrow-.

– Insert the fiber-optic cable into the brass pin contact -arrow-

all the way up to the threaded stop and then close the Fiber-

Optic Repair Set - Pliers - VAS6223/1- .

– Open the fiber-optic cable pliers and remove the fiber-optic

cable along with the brass contact pin.

Caution

Do not excessively bend or kink the fiber-optic cables (mini‐

mum bending radius 25 mm).

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fiber-optic cable -1-.

• 4 crimped points must be visible on the brass connecting pin.
• The brass pin contact must not be able to be removed by hand

from fiber-optic cable.

• The front surface of the fiber-optic cable is 0.01 to 0.1 mm

behind the brass pin contact (visual check).

Note

♦

Connector couplings are available for connecting the fiber-op‐

tic cables. Refer to Parts Catalog.

♦

To install the new fiber optic cable in wiring harness connector.

Refer to

⇒ “6.3 Fiber-Optic Cable, Disconnecting from Wiring Harness

Connector”, page 130

 .

Corrugated Tube, Install on Fiber Optic Cable.

– Cut the corrugated tube to the fitting length using Hose Cutting

Pliers - VAS6228- .

• The corrugated tube must be cut on the wave peak -arrow-,

not in the wave trough.

• Use the Hose Cutting Pliers - VAS6228- or a sharp knife for

cutting.

• The corrugated tube must not be cut using a side cutter under

any circumstances.

• The corrugated tube must audibly engage in the fiber-optic

cable housing when installing.

– Guide the fiber-optic cable into the Fiber-Optic Repair Set -

Tube Tool - VAS6223/10- .

– Position corrugated tube assembly pliers on slot on the tube.
– Position crimping pliers for fiber-optic cable at slot of corruga‐

ted tube. The fiber optic cable is then routed in the corrugated

tube.

Beetle 2012 ➤ , Golf 2015 ➤ , Golf Variant 2007 ➤ , Golf Variant 2010 ➤ ...

6. Fiber-Optic Cable    

129

Fiber-Optic Cable, Disconnecting from

Wiring Harness Connector

Removing
– Unplug connector for fiber optic cable from appropriate control

unit.

– Release the locking mechanism in the fiber-optic cable con‐

nector -1- by pushing on it.

– Release the secondary lock -2- with a small screwdriver.
– Remove the fiber-optic cable.

Caution

♦ Install the cap on the trunk, in order to protect the fiber-

optic cable from dust and dirt.

♦ Use a new housing since it is likely that the secondary lock

was damaged during the removal of the fiber-optic cable.

♦ Note the arrows on the base module for allocation “IN” and

“OUT”.

Installing
Install in the reverse order of removal. Note the following:
– Install the fiber-optic cable according to the markings.

Note

♦

Push the corrugated tube into the connector housing until it

audibly engages.

♦

Seal open fiber-optic cable connector -2- with Fiber-Optic Re‐

pair Set - Connector Protective Caps - VAS6223/9- -item 1-.

♦

The protective cap prevents contamination of or mechanical

damage to front surface of fiber optic cable which would impair

signal transmission.

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Heated Oxygen Sensor, Replacing

⇒ “7.1 Heated Oxygen Sensor, Replacing, 4-Pin Universal Oxy‐

gen Sensor”, page 131
⇒ “7.2 Heated Oxygen Sensor, Replacing, 6-Pin Universal Oxy‐

gen Sensor”, page 131
⇒ “7.3 Oxygen Sensor Unit Protective Pipes”, page 132

7.1

Heated Oxygen Sensor, Replacing, 4-

Pin Universal Oxygen Sensor

Use the faulty sensor as a guide for installing all of the accompa‐

nying attachments, cable ties or marking bands.
Do not repair the heated oxygen sensor wires. Repairing may re‐

sult in malfunctions.
Procedure
– Remove the faulty heated oxygen sensor.
– Lay both of the heated oxygen sensors next to each other so

the sensor housings are the same level.

– Tie the excess length of the sensor (approximately 50 to 250

mm) back so it is the same length as the faulty sensor and

secure it with cable ties -1-.

– Check if the heated oxygen sensor connector housing is com‐

patible with the vehicle electrical system side.

– Replace the vehicle electrical system connector with the pro‐

vided heated oxygen sensor connector housing. Refer to

⇒ “3.2 Connector Housings and Connectors, Repairing”, page

112

 .

Note

♦

Only replace the connector housing on older vehicles. The

connector housing is correct on new vehicles.

♦

Check the pin assignment. The individual pins in the new con‐

nector housing are marked with colors.

♦

The packaging for the new heated oxygen sensor contains

additional information.

– Install the new heated oxygen sensor in the vehicle.

7.2

Heated Oxygen Sensor, Replacing, 6-

Pin Universal Oxygen Sensor

Use the faulty sensor as a guide for installing all of the accompa‐

nying attachments, cable ties or marking bands.

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7. Heated Oxygen Sensor, Replacing    

131